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SAE-AISI 9254 Steel vs. 3003 Aluminum

SAE-AISI 9254 steel belongs to the iron alloys classification, while 3003 aluminum belongs to the aluminum alloys. There are 31 material properties with values for both materials. Properties with values for just one material (1, in this case) are not shown. Please note that the two materials have significantly dissimilar densities. This means that additional care is required when interpreting the data, because some material properties are based on units of mass, while others are based on units of area or volume.

For each property being compared, the top bar is SAE-AISI 9254 steel and the bottom bar is 3003 aluminum.

Metric UnitsUS Customary Units

Mechanical Properties

Brinell Hardness 200
28 to 65
Elastic (Young's, Tensile) Modulus, GPa 190
70
Elongation at Break, % 20
1.1 to 28
Fatigue Strength, MPa 280
39 to 90
Poisson's Ratio 0.29
0.33
Shear Modulus, GPa 72
26
Shear Strength, MPa 410
68 to 130
Tensile Strength: Ultimate (UTS), MPa 660
110 to 240
Tensile Strength: Yield (Proof), MPa 410
40 to 210

Thermal Properties

Latent Heat of Fusion, J/g 270
400
Maximum Temperature: Mechanical, °C 410
180
Melting Completion (Liquidus), °C 1440
650
Melting Onset (Solidus), °C 1400
640
Specific Heat Capacity, J/kg-K 480
900
Thermal Conductivity, W/m-K 46
180
Thermal Expansion, µm/m-K 13
23

Electrical Properties

Electrical Conductivity: Equal Volume, % IACS 7.4
44
Electrical Conductivity: Equal Weight (Specific), % IACS 8.6
140

Otherwise Unclassified Properties

Base Metal Price, % relative 2.2
9.5
Density, g/cm3 7.7
2.8
Embodied Carbon, kg CO2/kg material 1.5
8.1
Embodied Energy, MJ/kg 20
150
Embodied Water, L/kg 49
1180

Common Calculations

Resilience: Ultimate (Unit Rupture Work), MJ/m3 110
0.95 to 63
Resilience: Unit (Modulus of Resilience), kJ/m3 450
11 to 300
Stiffness to Weight: Axial, points 13
14
Stiffness to Weight: Bending, points 25
50
Strength to Weight: Axial, points 24
11 to 24
Strength to Weight: Bending, points 22
18 to 30
Thermal Diffusivity, mm2/s 12
71
Thermal Shock Resistance, points 20
4.7 to 10

Alloy Composition

Aluminum (Al), % 0
96.8 to 99
Carbon (C), % 0.51 to 0.59
0
Chromium (Cr), % 0.6 to 0.8
0
Copper (Cu), % 0
0.050 to 0.2
Iron (Fe), % 96.1 to 97.1
0 to 0.7
Manganese (Mn), % 0.6 to 0.8
1.0 to 1.5
Phosphorus (P), % 0 to 0.035
0
Silicon (Si), % 1.2 to 1.6
0 to 0.6
Sulfur (S), % 0 to 0.040
0
Zinc (Zn), % 0
0 to 0.1
Residuals, % 0
0 to 0.15